Method and device for controlling liquid level of molten glass in kiln, terminal and medium

Abstract

The invention provides a method and device for controlling the liquid level of molten glass in a kiln, a terminal and a medium. The method comprises the following steps: acquiring structural parameters and thermal parameters of the kiln; based on the structural parameters and the thermal parameters, constructing a dynamic mathematical model for describing the liquid level change of the molten glass; the target function of the dynamic mathematical model is used for measuring the deviation between the actual liquid level height and the ideal liquid level height of the molten glass in the kiln; calculating an optimal control law that minimizes an objective function of the dynamic mathematical model based on a linear quadratic regulator algorithm; and adjusting the liquid level height of the molten glass in the kiln based on the optimal control law. According to the method, the dynamic mathematical model used for describing the liquid level change of the molten glass is constructed, the deviation minimization between the actual liquid level height and the ideal liquid level height of the molten glass in the kiln serves as the target, the optimal control strategy is determined, and high-precision stable control over the liquid level height of the molten glass in the kiln is achieved.

Description

Technical Field

[0001] This application belongs to the technical field of glass production, and relates to a method, device, terminal and medium for controlling the liquid level of glass liquid in a kiln furnace. Background Art

[0002] As an important material widely used in many fields such as construction, automobiles, and electronics, the accuracy and stability of the production process of glass play a decisive role in product quality. The glass production process begins with mixing various glass raw materials according to a specific formula, and then conveying them to a high-temperature kiln furnace through a feeding machine. Inside the kiln furnace, the glass raw materials will undergo complex physical and chemical reactions and gradually melt into a uniform glass liquid.

[0003] The quality of glass products depends to a large extent on the process conditions inside the kiln furnace, and among them, the stable control of the liquid level height of the glass liquid is particularly crucial. A stable liquid level height can not only ensure uniform heating of the glass liquid in the kiln furnace and promote full chemical reactions, but also has a profound impact on aspects such as the thickness uniformity, optical properties, and mechanical properties of the glass in subsequent glass forming processes. For example, if the liquid level of the glass liquid fluctuates too much, it may cause defects such as thickness deviation and stress concentration in the product, thereby reducing the yield rate of the product.

[0004] The traditional method is to adjust the liquid level height of the glass liquid by controlling the feeding machine. However, when faced with the complex thermal environment inside the kiln furnace, changes in raw material characteristics, and external disturbances, the feeding machine control method exposes many limitations. For example, the control accuracy is difficult to meet the strict requirements of modern glass production for high quality and high efficiency, and it is easy to cause large fluctuations in the liquid level height, thus affecting the consistency and stability of the product. In addition, the adaptability of the traditional feeding machine control method is poor. When production process parameters or working conditions change, a large amount of manual debugging and intervention is required, which not only increases labor costs but also reduces production efficiency. Summary of the Invention

[0005] The purpose of this application is to provide a method, device, terminal and medium for controlling the liquid level of glass liquid in a kiln furnace, which is used to solve the technical problems of low control accuracy and poor stability of the liquid level height of glass liquid in the prior art under complex working conditions.

[0006] In a first aspect, the present application provides a method for controlling the liquid level of glass liquid in a kiln, including: obtaining the structural parameters and thermal parameters of the kiln; the structural parameters include the cross-sectional area of the kiln; the thermal parameters include the liquid level height of the glass liquid in the kiln, the temperature inside the kiln, the feeding rate of the feeder, and the discharging flow rate of the kiln; based on the structural parameters and the thermal parameters, constructing a dynamic mathematical model for describing the change of the glass liquid level; the objective function of the dynamic mathematical model is used to measure the deviation between the actual liquid level height and the ideal liquid level height of the glass liquid in the kiln; based on the linear quadratic regulator algorithm, calculating an optimal control law that minimizes the objective function of the dynamic mathematical model; based on the optimal control law, adjusting the liquid level height of the glass liquid in the kiln.

[0007] In an implementation manner of the first aspect, constructing a dynamic mathematical model for describing the change of the glass liquid level based on the structural parameters and the thermal parameters includes: calculating the melting rate of the glass raw material based on the liquid level height of the glass liquid in the kiln and the temperature inside the kiln; calculating the net generation rate of the glass liquid in the kiln based on the feeding rate of the feeder, the discharging flow rate of the kiln, and the melting rate of the glass raw material; the net generation rate of the glass liquid in the kiln is equal to the result of adding the difference between the feeding rate of the feeder and the discharging flow rate of the kiln to the melting rate of the glass raw material; dividing the net generation rate of the glass liquid in the kiln by the cross-sectional area of the kiln to obtain the dynamic mathematical model.

[0008] In an implementation manner of the first aspect, the dynamic mathematical model for describing the change of the glass liquid level is expressed as:

[0009]

[0010] where h(t) represents the liquid level height of the glass liquid in the kiln; u(t) represents the feeding rate of the feeder; q d represents the discharging flow rate of the kiln; r(h(t), T(t)) represents the melting rate of the glass raw material; T(t) represents the temperature inside the kiln; S represents the cross-sectional area of the kiln.

[0011] In an implementation of the first aspect, based on the linear quadratic regulator algorithm, calculating the optimal control law that minimizes the objective function of the dynamic mathematical model includes: linearizing the dynamic mathematical model to obtain a state-space model; the objective function of the state-space model is a quadratic performance index function; obtaining the state transition matrix and the control input matrix that constitute the state-space model; obtaining the state weight matrix and the control input weight matrix that constitute the quadratic performance index function; solving the Riccati equation based on the state transition matrix, the control input matrix, and the state weight matrix to obtain the solution of the Riccati equation; generating the optimal control law based on the solution of the Riccati equation, the control input matrix, and the control input weight matrix.

[0012] In an implementation of the first aspect, it further includes: setting specific constraint conditions according to the actual process requirements of the kiln and the equipment operation limitations; the specific constraint conditions include the feeding rate constraint of the feeder, the capacity constraint of the kiln, and the liquid level constraint of the glass melt; under the specific constraint conditions, based on the linear quadratic regulator algorithm, calculating the optimal control law that minimizes the objective function of the dynamic mathematical model.

[0013] In an implementation of the first aspect, based on the optimal control law, adjusting the liquid level height of the glass melt in the kiln includes: generating multiple control instructions in the glass production process based on the optimal control law; the multiple control instructions in the glass production process include motor speed control instructions, valve opening control instructions, and the start-stop frequency control instructions of the feeder; in response to the motor speed control instructions, adjusting the feeding rate of the feeder; in response to the valve opening control instructions, adjusting the discharge flow rate of the kiln; in response to the start-stop frequency control instructions of the feeder, optimizing the start-stop time interval of the feeder.

[0014] In an implementation of the first aspect, it further includes introducing an adaptive adjustment mechanism to suppress external system disturbances, where the processing steps of the adaptive adjustment mechanism include: real-time monitoring of the unstable factors affecting the glass production process; the unstable factors include the composition fluctuations of the glass raw materials, the changes in the thermal environment of the kiln, and the abnormalities in the discharge flow rate of the kiln; based on the unstable factors, dynamically correcting the state transition matrix and the control input matrix that constitute the state-space model, and the state weight matrix and the control input weight matrix that constitute the quadratic performance index function.

[0015] Second aspect, the present application provides a device for controlling the liquid level of glass melt in a kiln, including: a data acquisition module for acquiring the structural parameters and thermal parameters of the kiln; the structural parameters include the cross-sectional area of the kiln; the thermal parameters include the liquid level height of the glass melt in the kiln, the temperature inside the kiln, the feeding rate of the feeder, and the discharging flow rate of the kiln; a model construction module for constructing a dynamic mathematical model for describing the change of the liquid level of the glass melt based on the structural parameters and the thermal parameters; the objective function of the dynamic mathematical model is used to measure the deviation between the actual liquid level height and the ideal liquid level height of the glass melt in the kiln; a model optimization module for calculating an optimal control law that minimizes the objective function of the dynamic mathematical model based on the linear quadratic regulator algorithm; a liquid level control module for adjusting the liquid level height of the glass melt in the kiln based on the optimal control law.

[0016] Third aspect, the present application provides a terminal, including: a processor and a memory; the memory is used for storing a computer program; the processor is used for executing the computer program stored in the memory so that the terminal executes the method described in any one of the above.

[0017] Fourth aspect, the present application provides a computer-readable storage medium, on which a computer program is stored, and when the program is executed by a processor, the method described in any one of the above is implemented.

[0018] As described above, the method, device, terminal and medium for controlling the liquid level of glass melt in the kiln according to the present application have the following beneficial effects:

[0019] (1) By constructing a dynamic mathematical model for describing the change of the liquid level of the glass melt, and taking minimizing the deviation between the actual liquid level height and the ideal liquid level height of the glass melt in the kiln as the goal, the present application determines an optimal control strategy and realizes high-precision and stable control of the liquid level height of the glass melt in the kiln.

[0020] (2) The present application can not only ensure the consistency of the physical properties of the glass melt in the melting furnace, provide a stable raw material basis for the subsequent glass product forming process, but also significantly improve the quality stability and qualification rate of glass products, and guarantee the product quality from the source. Description of the Drawings

[0021] Figure 1 It shows a schematic structural diagram of the mobile terminal described in an embodiment of the present application in one embodiment.

[0022] Figure 2 It shows a flowchart of the method for controlling the liquid level of glass melt in the kiln according to the present application in one embodiment.

[0023] Figure 3 It shows a flowchart of model construction of the method for controlling the liquid level of glass melt in the kiln according to the present application in one embodiment.

[0024] Figure 4 It shows the calculation flowchart of the optimal control law in an embodiment of the method for controlling the liquid level of the furnace glass liquid described in this application.

[0025] Figure 5 It shows the flowchart of adjusting the liquid level height in an embodiment of the method for controlling the liquid level of the furnace glass liquid described in this application.

[0026] Figure 6 It shows the structural schematic diagram of the device for controlling the liquid level of the furnace glass liquid described in this application in an embodiment.

[0027] Figure 7 It shows the structural schematic diagram of the terminal described in this application in an embodiment. Detailed implementation manners

[0028] The following uses specific specific examples to illustrate the implementation manners of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. This application can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0029] It should be noted that the diagrams provided in the following embodiments only illustrate the basic concept of this application in a schematic manner. Therefore, only the components related to this application are shown in the diagrams, rather than being drawn according to the number, shape, and size of the components in actual implementation. The types, quantities, and proportions of the components in actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0030] In addition, in this application, descriptions such as "first" and "second" are only for descriptive purposes, and cannot be understood as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" can explicitly or implicitly include at least one of these features. In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on the ability of those of ordinary skill in the art to implement. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection required by this application.

[0031] The following embodiments of the present application provide a method, device, terminal and medium for controlling the liquid level of glass liquid in a kiln. By constructing a dynamic mathematical model for describing the change of the glass liquid level, and taking the minimization of the deviation between the actual liquid level height and the ideal liquid level height of the glass liquid in the kiln as the goal, the optimal control strategy is determined, realizing high-precision and stable control of the liquid level height of the glass liquid in the kiln. In addition, the present application can not only ensure the consistency of the physical properties of the glass liquid in the melting furnace, provide a stable raw material basis for the subsequent glass product forming process, but also significantly improve the quality stability and qualification rate of glass products, guaranteeing the product quality from the source.

[0032] Please refer to Figure 1 As shown, the method for controlling the liquid level of glass liquid provided by the embodiments of the present application can run on similar devices such as mobile terminals and computer terminals. Taking running on the mobile terminal as an example, Figure 1 is the hardware structure block diagram of the mobile terminal, as Figure 1 Taking one mobile terminal as an example, the mobile terminal may include: a processor and a memory. The processor may be a central processing unit, and the memory is used to store data. Figure 1 The mobile terminal in

[0033] is only for illustration and does not limit the specific structure of the mobile terminal.

[0034] Optionally, the memory may be used to store computer programs, such as software programs and modules of application software. The memory may include high-speed random access memory, and may also include non-volatile memory, such as one or more magnetic storage devices, flash memory, or other non-volatile solid-state memories. In some instances, the memory may further include a memory remotely set relative to the processor, and these remote memories may be connected to the mobile terminal through a network. Examples of the above networks include but are not limited to the Internet, enterprise intranets, local area networks, mobile communication networks, and their combinations.

[0035] Optionally, the communication transmission device may be used to receive or send data via a network. The network may include a wireless network provided by the communication provider of the mobile terminal. The communication transmission device may include a NIC (Network Interface Controller), which can be connected to other network devices through a base station and thus communicate with the Internet.

[0036] Next, the technical solutions in the embodiments of the present application will be described in detail with reference to the accompanying drawings in the embodiments of the present application.

[0037] Please refer to Figure 2, which shows the flow chart of the method for controlling the liquid level of the glass melt in the kiln according to an embodiment of the present application.

[0038] As Figure 2 shown, this embodiment provides a method for controlling the liquid level of the glass melt in the kiln, including the following steps S100 to S400.

[0039] In step S100, the structural parameters and thermal parameters of the kiln are obtained; the structural parameters include the cross-sectional area of the kiln; the thermal parameters include the liquid level height of the glass melt in the kiln, the temperature in the kiln, the feeding rate of the feeder, and the discharging flow rate of the kiln.

[0040] Specifically, the cross-sectional area of the kiln can be expressed as S, and the value of S is determined by the geometric design of the melting furnace and belongs to static constant parameters. S can be directly obtained from engineering drawings or measured non-contact with the kiln body by a laser scanner or three-dimensional modeling technology. The liquid level height of the glass melt in the kiln can be expressed as h(t), where h(t) is a function of time and is used to reflect the liquid level height of the glass melt at different times in the kiln. h(t) can be measured by a liquid level sensor. The temperature in the kiln can be expressed as T(t), where T(t) is a function of time and is used to reflect the temperature at different times in the kiln. T(t) can be measured by temperature sensors distributed at different positions in the kiln. The feeding rate of the feeder can be expressed as u(t), where u(t) is a function of time and is used as a control variable to reflect the feeding rate of the feeder at different times. The discharging flow rate of the melting furnace can be expressed as q d , in the actual production process, q d can be approximately regarded as a constant.

[0041] In this implementation, the structural parameters and thermal parameters of the kiln, as the basis for the feedback of system state variables, can provide real-time and accurate data support for the implementation of subsequent control decisions.

[0042] In step S200, based on the structural parameters and the thermal parameters, a dynamic mathematical model for describing the change of the liquid level of the glass melt is constructed; the objective function of the dynamic mathematical model is used to measure the deviation between the actual liquid level height and the ideal liquid level height of the glass melt in the kiln.

[0043] Please refer to Figure 3 , which shows the flow chart of model construction in an embodiment of the method for controlling the liquid level of the glass melt in the kiln according to the present application.

[0044] In an embodiment of the present application, constructing a dynamic mathematical model for describing the change of the liquid level of the glass melt based on the structural parameters and the thermal parameters includes the following steps S201 to S203.

[0045] In step S201, based on the liquid level height of the molten glass in the kiln and the temperature inside the kiln, calculate the melting rate of the glass raw materials.

[0046] Specifically, the melting rate of the glass raw materials can be expressed as a binary function relation with respect to the liquid level height h of the molten glass in the kiln and the temperature T inside the kiln:

[0047] r(h(t), T(t)) = αh(t) + βT(t) + γ

[0048] Where r(h(t), T(t)) represents the melting rate of the glass raw materials; h(t) represents the liquid level height of the molten glass in the kiln; T(t) represents the temperature inside the kiln; α, β, and γ are coefficients related to the characteristics of the glass raw materials and the kiln process.

[0049] In step S202, based on the feeding rate of the feeder, the discharge flow rate of the kiln, and the melting rate of the glass raw materials, calculate the net production rate of the molten glass in the kiln; the net production rate of the molten glass in the kiln is equal to the result of adding the difference between the feeding rate of the feeder and the discharge flow rate of the kiln to the melting rate of the glass raw materials.

[0050] Specifically, the net production rate of the molten glass in the kiln = the feeding rate u(t) of the feeder - the discharge flow rate q d + the melting rate r(h(t), T(t)) of the glass raw materials.

[0051] In step S203, divide the net production rate of the molten glass in the kiln by the cross-sectional area of the kiln to obtain the dynamic mathematical model.

[0052] In an embodiment of the present application, the dynamic mathematical model used to describe the change in the liquid level of the molten glass is expressed as:

[0053]

[0054] Where h(t) represents the liquid level height of the molten glass in the kiln; u(t) represents the feeding rate of the feeder; q d represents the discharge flow rate of the kiln; r(h(t), T(t)) represents the melting rate of the glass raw materials; T(t) represents the temperature inside the kiln; S represents the cross-sectional area of the kiln.

[0055] The dynamic mathematical model established in the present application strictly follows the principle of material balance. Based on the dynamic mathematical model, factors such as the feeding rate of the feeder, the discharge flow rate of the kiln, the melting rate of the glass raw materials, and the cross-sectional area of the kiln that affect the change in the liquid level of the molten glass can be analyzed.

[0056] In the present application, the liquid level height of the molten glass is to be stabilized at a preset ideal liquid level height hset Taking the vicinity as the main target, a corresponding objective function is constructed.

[0057] In an embodiment of the present application, the objective function of the dynamic mathematical model can be expressed as:

[0058]

[0059] where h(t) represents the liquid level height of the molten glass in the glass furnace; h set represents the ideal liquid level height; λ is a weight coefficient used to balance the importance between the liquid level deviation and the control amount of the feeding rate of the feeder; u(t) is the feeding rate of the feeder; t0 represents the starting time of the control process; t f represents the ending time of the control process.

[0060] After establishing a dynamic mathematical model for describing the change of the molten glass liquid level, the present application adopts the Linear Quadratic Regulator (LQR) method for system optimal control. The LQR method is an optimal control strategy based on the state space model of a linear system. The present application constructs a quadratic performance index function and solves the corresponding Riccati equation to obtain the optimal control law of the system.

[0061] Compared with the traditional Proportional Integral Derivative (PID) control method, LQR can not only ensure the asymptotic stability of the closed-loop system, but also achieve multi-objective optimization by adjusting the weight matrix, and is particularly suitable for the industrial process control of glass melting furnaces with strong coupling and large inertia characteristics described in the embodiments of the present application.

[0062] In step S300, based on the linear quadratic regulator algorithm, an optimal control law that minimizes the objective function of the dynamic mathematical model is calculated.

[0063] Please refer to Figure 4 , which shows the flow chart of calculating the optimal control law in an embodiment of the method for controlling the liquid level of the molten glass in the furnace described in the present application.

[0064] In an embodiment of the present application, calculating an optimal control law that minimizes the objective function of the dynamic mathematical model based on the linear quadratic regulator algorithm includes the following steps S301 to S305.

[0065] In step S301, the dynamic mathematical model is linearized to obtain a state space model; the objective function of the state space model is a quadratic performance index function.

[0066] In this implementation manner, by linearizing the dynamic mathematical model, a state space model applicable to linear control theory analysis can be obtained.

[0067] It should be noted that the linearization method adopted in this embodiment is a prior art means, so this application will not describe it in detail herein.

[0068] In step S302, obtain the state transition matrix and the control input matrix that constitute the state space model.

[0069] In an embodiment of the present application, the state space form obtained by linearization can be expressed as:

[0070] x′(t) = Ax(t) + Bu(t)

[0071] Where x(t) is the system state vector. In this embodiment, the system state vector may include the liquid level height h(t) of the molten glass in the furnace and its change rate; u(t) is the control input vector, representing the feeding rate of the feeder; A is the state transition matrix, used to describe the internal dynamic characteristics of the system; B is the control input matrix, used to associate the control input vector with the system state vector.

[0072] In step S303, obtain the state weight matrix and the control input weight matrix that constitute the quadratic performance index function.

[0073] In an embodiment of the present application, the quadratic performance index function can be expressed as:

[0074]

[0075] Where t0 represents the starting time of the control process; x(t) is the system state vector. In this embodiment, the state vector may include the liquid level height h(t) of the molten glass in the furnace and its change rate; u(t) is the control input vector, which represents the feeding rate of the feeder in this embodiment; Q is a semi - positive definite state weight matrix, used to emphasize the requirements for the control accuracy of different state vectors. Specifically, larger weights can be assigned to the corresponding elements in the matrix according to the importance of liquid level control; R is a positive definite control weight matrix, which can adjust the magnitude of the control quantity to balance factors such as control effect and control energy consumption. For example, the weight setting of the control quantity of the feeding rate of the feeder affects its change range in the optimization process.

[0076] In step S304, based on the state transition matrix, the control input matrix, and the state weight matrix, solve the Riccati equation to obtain the solution of the Riccati equation.

[0077] In an embodiment of the present application, the Riccati equation can be expressed as:

[0078] PA + A T P - PBR -1 B T P + Q = 0

[0079] In the Riccati equation, A is the state transition matrix, B is the control input matrix, Q is the positive semi - definite state weight matrix, and only P is unknown. By solving the Riccati equation, a unique positive definite symmetric matrix P can be obtained.

[0080] In step S305, based on the solution of the Riccati equation, the control input matrix, and the control input weight matrix, the optimal control law is generated.

[0081] In an embodiment of the present application, the optimal control law can be expressed as:

[0082] u(t)= - R -1 B T Px(t)

[0083] Where R is the positive definite control weight matrix, B is the control input matrix, P is the solution of the Riccati equation, x(t) is the system state vector. In this embodiment, the state vector can include the liquid level height h(t) of the molten glass in the furnace and its change rate, and u(t) is the control input vector, representing the feeding rate of the feeder.

[0084] In step S400, based on the optimal control law, the liquid level height of the molten glass in the furnace is adjusted.

[0085] Please refer to Figure 5 , which shows the liquid level height adjustment flow chart in an embodiment of the molten glass liquid level control method described in the present application.

[0086] In an embodiment of the present application, adjusting the liquid level height of the molten glass in the furnace based on the optimal control law includes the following steps S401 to S404.

[0087] In step S401, based on the optimal control law, multiple control instructions in the glass production process are generated; the multiple control instructions in the glass production process include motor speed control instructions, valve opening control instructions, and feeder start - stop frequency control instructions.

[0088] It should be noted that in the glass production process, in addition to the motor speed, valve opening, and feeder start - stop frequency, the following control instructions can also be generated based on the control law to further optimize the adjustment of the liquid level height, improve system stability, energy efficiency, or production quality:

[0089] (1) Temperature control instructions can indirectly affect the discharge flow rate and liquid level stability by adjusting the temperature in the kiln and changing the viscosity of the molten glass. The control logic of the temperature control instructions includes high-temperature compensation: if the liquid level is low and the discharge flow rate is insufficient (due to high viscosity), increase the temperature to reduce the viscosity and increase the discharge flow rate; low-temperature suppression: if the liquid level fluctuates violently, appropriately reduce the temperature to increase the viscosity and slow down the discharge speed.

[0090] (2) Pressure balance control instructions can adjust the internal air pressure of the kiln to prevent air pressure fluctuations from affecting the discharge flow rate (especially for closed kilns). The control logic of the pressure balance control instructions includes negative pressure compensation: if the liquid level continues to drop and the discharge flow rate is abnormal, increase the intake air volume to balance the air pressure in the furnace; overpressure release: when the liquid level rises suddenly, open the exhaust valve to prevent bubble disturbance.

[0091] In this implementation, by expanding the control instruction set, it is possible to more comprehensively address complex disturbances and non-linear problems in glass liquid level control, while improving energy efficiency and equipment life. In practical applications, it is necessary to combine the process characteristics and verify the effectiveness of the control strategy through experiments or digital twins.

[0092] In step S402, in response to the motor speed control instruction, adjust the feeding rate of the feeder.

[0093] In the embodiment of the present application, the motor speed directly controls the feeding speed of the feeder. The higher the motor speed, the more glass raw materials are fed into the kiln per unit time, and the liquid level increases after melting into molten glass; conversely, when the motor speed decreases, the feeding amount decreases and the liquid level drops.

[0094] In practical applications, factors such as the mechanical characteristics, electrical parameters, and load characteristics of the motor will affect its response speed and accuracy to the motor speed control instruction. When generating the motor speed control instruction based on the optimal control law in the present application, these factors can be considered, and by accurately modeling the motor model, the dynamic changes of the motor speed under different control inputs can be predicted, so as to achieve more precise control of the feeding rate of the feeder.

[0095] In step S403, in response to the valve opening control instruction, adjust the discharge flow rate of the kiln.

[0096] The valve is usually located at the kiln outlet or the liquid flow hole, and the outflow speed of the molten glass can be adjusted by adjusting the valve opening. When the opening increases, the discharge flow rate increases and the liquid level drops; when the opening decreases, the discharge slows down and the liquid level rises.

[0097] The optimal control law can calculate the optimal valve opening according to the current liquid level state, the expected liquid level change trend, and other constraints of the system. For example, when the liquid level is close to the set upper limit and still has an upward trend, the optimal control law will instruct the valve to reduce the opening or even close for a period of time to reduce the inflow of materials and prevent the liquid level from being too high. This adjustment is based on the optimization of the dynamic model and performance indicators of the entire system, aiming to make the liquid level quickly and stably approach the set value and remain within the allowable error range.

[0098] In step S404, in response to the start-stop frequency control instruction of the batcher, optimize the start-stop time interval of the batcher.

[0099] This application indirectly adjusts the feeding amount of glass raw materials by controlling the start-stop frequency of the batcher, thereby further optimizing the regulation of the liquid level height.

[0100] The optimal control law formulates a reasonable start-stop plan for the batcher by comprehensively considering factors such as production demand, equipment status, and production economy. For example, in the process of glass production, if the batcher is frequently started and stopped, it will cause frequent acceleration and deceleration of the motor, increasing energy consumption and equipment wear. The optimal control law will calculate the best start-stop time interval of the batcher according to factors such as the current liquid level situation, the expected duration of the production task, and the start-up cost of the equipment. When the liquid level is low but still within the safe range and it is expected that it will not be lower than the minimum liquid level for a long time, the optimal control law may delay the start of the batcher to reduce unnecessary start-stop times.

[0101] In this implementation manner, the start-stop optimization strategy of the batcher based on the control law can effectively control the start-stop frequency of the batcher. While ensuring the liquid level control accuracy, it significantly reduces the frequent switching of control actions, effectively suppresses the excessive fluctuation of the control quantity, avoids frequent start-stop operations of the batcher, and reduces equipment wear and energy consumption waste.

[0102] The experimental results show that this control method can reduce the start-stop frequency of the batcher by about 42%, thus effectively alleviating the wear problem of mechanical components. This optimization not only extends the service life of the equipment (it is expected to be extended by 30%-45%), but also significantly reduces the maintenance cost (the annual maintenance cost is reduced by about 25%), providing a reliable guarantee for the continuous and stable operation of the production process.

[0103] It should be noted that the LQR method is essentially a control strategy based on the assumption of a linear system. In the actual glass melting furnace system, there may be nonlinear factors such as temperature gradient changes and material property fluctuations. To address this limitation, this application can further combine other nonlinear compensation strategies to ensure the reliability and stability of the control effect.

[0104] In an embodiment of the present application, the method for controlling the liquid level of the glass melt in the furnace further includes: setting specific constraint conditions according to the actual process requirements of the furnace and the equipment operation limitations; the specific constraint conditions include the feeding rate constraint of the batch charger, the capacity constraint of the furnace, and the liquid level constraint of the glass melt; under the specific constraint conditions, based on the linear quadratic regulator algorithm, calculating the optimal control law that minimizes the objective function of the dynamic mathematical model.

[0105] Specifically, the feeding rate constraint of the batch charger includes: defining the upper threshold V_max and the lower threshold V_min of the feeding rate of the batch charger, and constructing the mathematical expression: V_min ≤ V(t) ≤ V_max, where V(t) represents the actual feeding rate at time t. By constraining the feeding rate of the batch charger, abnormal conditions such as equipment overload or insufficient feeding caused by improper control strategies can be effectively avoided.

[0106] The capacity constraint of the furnace includes: defining that the total amount of glass raw materials Q_total does not exceed the maximum designed capacity Q_max of the furnace, that is: Q_total(t) ≤ Q_max. By constraining the capacity of the furnace, it can be ensured that the production process is always within the safe load range of the equipment.

[0107] The liquid level constraint of the glass includes: defining the minimum safe liquid level height h_min, satisfying: h(t) ≥ h_min, where h(t) is the real-time monitored liquid level height of the glass. By constraining the liquid level of the glass, the stability and safety of the production process can be guaranteed.

[0108] In this implementation manner, it can be ensured that the entire control process operates within the safe boundary that meets the requirements of the glass production process.

[0109] In an embodiment of the present application, the method for controlling the liquid level of the glass melt in the furnace further includes introducing an adaptive adjustment mechanism to suppress external interference of the system, where the processing steps of the adaptive adjustment mechanism include: real-time monitoring of the unstable factors affecting the glass production process; the unstable factors include the composition fluctuations of the glass raw materials, the changes in the thermal environment of the furnace, and the abnormalities in the discharge flow rate of the furnace; based on the unstable factors, dynamically correcting the state transition matrix and the control input matrix that constitute the state space model, and the state weight matrix and the control input weight matrix that constitute the quadratic performance index function.

[0110] In this implementation method, by introducing an adaptive adjustment mechanism, the anti-interference ability of the system is enhanced, ensuring stable operation under complex working conditions and significantly improving the accuracy and stability of liquid level control. By dynamically optimizing control parameters, the need for manual intervention can be reduced, thereby improving the automation level and overall operation reliability of glass production, providing solid strategic support and technical guarantee for the efficient and high-quality production of the glass industry.

[0111] It should be noted that the protection scope of the method for controlling the liquid level of furnace glass liquid described in the embodiments of the present application is not limited to the execution order of the steps listed in this embodiment. Any solution achieved by adding or reducing steps of the prior art and replacing steps according to the principle of the present application is included in the protection scope of the present application.

[0112] Please refer to Figure 6 , which shows the structural schematic diagram of the device for controlling the liquid level of furnace glass liquid described in the present application in an embodiment.

[0113] As Figure 6 shown, this embodiment provides a device for controlling the liquid level of furnace glass liquid, including a data acquisition module, a model construction module, a model optimization module, and a liquid level control module.

[0114] The data acquisition module is used to acquire the structural parameters and thermal parameters of the furnace; the structural parameters include the cross-sectional area of the furnace; the thermal parameters include the liquid level height of the glass liquid in the furnace, the temperature in the furnace, the feeding rate of the feeder, and the discharging flow rate of the furnace.

[0115] The model construction module is used to construct a dynamic mathematical model for describing the change of the liquid level of the glass liquid based on the structural parameters and the thermal parameters; the objective function of the dynamic mathematical model is used to measure the deviation between the actual liquid level height and the ideal liquid level height of the glass liquid in the furnace.

[0116] The model optimization module is used to calculate the optimal control law that minimizes the objective function of the dynamic mathematical model based on the linear quadratic regulator algorithm.

[0117] The liquid level control module is used to adjust the liquid level height of the glass liquid in the furnace based on the optimal control law.

[0118] It should be noted that the structures and principles of the data acquisition module, the model construction module, the model optimization module, and the liquid level control module described in the embodiments of the present application correspond one by one to the steps in the above method for controlling the liquid level of furnace glass liquid, so they will not be elaborated here.

[0119] The furnace glass liquid level control device provided by the embodiments of the present application can implement the furnace glass liquid level control method described in the present application. However, the implementation devices of the furnace glass liquid level control method described in the present application include, but are not limited to, the structures of the furnace glass liquid level control devices listed in this embodiment. Any structural deformation and substitution of the prior art made according to the principle of the present application are included in the protection scope of the present application.

[0120] Please refer to Figure 7 , which shows the structural schematic diagram of the terminal described in the present application in one embodiment.

[0121] As Figure 7 shown, this embodiment provides a terminal, including: a processor and a memory.

[0122] The memory is used to store computer programs.

[0123] The processor is used to execute the computer program stored in the memory, so that the terminal executes the method described in any one of the above.

[0124] In one embodiment of the present application, the processor may be a general-purpose processor, including a central processing unit (CPU for short), a network processor (NP for short), etc.; it may also be a digital signal processor (DSP for short), an application-specific integrated circuit (ASIC for short), a field programmable gate array (FPGA for short), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components. The memory may be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (SRAM), electrically erasable programmable read-only memory (EEPROM), erasable programmable read-only memory (EPROM), programmable read-only memory (PROM), read-only memory (ROM), magnetic memory, flash memory, a magnetic disk or an optical disc.

[0125] This embodiment also includes one or more of a multimedia component, an input / output (I / O) interface, and a communication component.

[0126] The multimedia component may include a screen and an audio component. The screen may be, for example, a touch screen. The audio component is used to output and / or input audio signals. For example, the audio component may include a microphone for receiving external audio signals. The received audio signals may be further stored in the memory or transmitted via the communication component. The audio component also includes at least one speaker for outputting audio signals. The I / O interface provides an interface between the processor and other interface modules, which may be a keyboard, a mouse, buttons, etc. These buttons may be virtual buttons or physical buttons. The communication component is used for wired or wireless communication between this timer and other devices. Wireless communication, such as Wi-Fi, Bluetooth, Near Field Communication (NFC), 2G, 3G, or 4G, or a combination of one or more of them. Accordingly, the communication component may include: a Wi-Fi module, a Bluetooth module, and an NFC module.

[0127] In several embodiments provided in this application, it should be understood that the disclosed system, apparatus, or method may be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative. For example, the division of modules / units is only a logical function division, and there may be other division methods in actual implementation. For example, multiple modules or units may be combined or integrated into another system, or some features may be ignored or not executed. Another point is that the displayed or discussed couplings or direct couplings or communication connections to each other may be through some interfaces, and the indirect couplings or communication connections of devices or modules or units may be in electrical, mechanical, or other forms.

[0128] The modules / units described as separate components may or may not be physically separated. The components shown as modules / units may or may not be physical modules, that is, they may be located in one place or distributed to multiple network units. Some or all of the modules / units may be selected according to actual needs to achieve the purpose of the embodiments of this application. For example, in each embodiment of this application, the functional modules / units may be integrated in a processing module, or each module / unit may exist physically alone, or two or more modules / units may be integrated in one module / unit.

[0129] Those of ordinary skill in the art should also be further aware that the units and algorithm steps of each example described in combination with the embodiments disclosed herein can be implemented by electronic hardware, computer software, or a combination of the two. To clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described according to functions in the above description. Whether these functions are executed in a hardware or software manner depends on the specific application and design constraints of the technical solution. A professional technician can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of this application.

[0130] The embodiments of this application also provide a computer-readable storage medium, on which a computer program is stored, and when the program is executed by a processor, the method described in any one of the above is implemented. Those of ordinary skill in the art can understand that all or part of the steps in the method of implementing the above embodiments can be completed by instructing the processor through a program. The described program can be stored in a computer-readable storage medium. The storage medium is a non-transitory medium, such as random access memory, read-only memory, flash memory, hard disk, solid-state drive, magnetic tape, floppy disk, optical disc, and any combination thereof. The above storage medium can be any available medium that a computer can access or a data storage device such as a server or data center that includes one or more integrated available media. The available medium can be a magnetic medium (such as a floppy disk, hard disk, magnetic tape), an optical medium (such as a digital video disc (DVD)), or a semiconductor medium (such as a solid-state disk (SSD)).

[0131] The embodiments of this application can also provide a computer program product, which includes one or more computer instructions. When the computer instructions are loaded and executed on a computing device, the processes or functions described in the embodiments of this application are fully or partially generated. The computer instructions can be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium. For example, the computer instructions can be transmitted from a website, computer, or data center to another website, computer, or data center in a wired manner (such as coaxial cable, optical fiber, digital subscriber line (DSL)) or a wireless manner (such as infrared, wireless, microwave, etc.).

[0132] When the computer program product is executed by a computer, the computer executes the method described in the foregoing method embodiments. The computer program product can be a software installation package. In the case where the foregoing method needs to be used, the computer program product can be downloaded and executed on the computer.

[0133] The descriptions of the processes or structures corresponding to the foregoing various drawings each have their own focuses. For parts not detailed in a certain process or structure, reference can be made to the relevant descriptions of other processes or structures.

[0134] The foregoing embodiments are merely illustrative of the principles and effects of the present application, and are not intended to limit the present application. Any person familiar with this technology can modify or change the foregoing embodiments without departing from the spirit and scope of the present application. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the technical field without departing from the spirit and technical ideas disclosed in the present application should still be covered by the claims of the present application.

Claims

1. A method for controlling the liquid level of glass liquid in a kiln, characterized in that, Including: Obtain the structural parameters and thermal parameters of the kiln; the structural parameters include the cross-sectional area of the kiln; the thermal parameters include the liquid level height of the molten glass in the kiln, the temperature in the kiln, the feeding rate of the feeder, and the discharge flow rate of the kiln. Based on the structural parameters and the thermal parameters, construct a dynamic mathematical model for describing the change in the liquid level of the molten glass; the objective function of the dynamic mathematical model is used to measure the deviation between the actual liquid level height and the ideal liquid level height of the molten glass in the kiln. Based on the linear quadratic regulator algorithm, calculate the optimal control law that minimizes the objective function of the dynamic mathematical model. Based on the optimal control law, adjust the liquid level height of the molten glass in the kiln.

2. The method according to claim 1, wherein Based on the structural parameters and the thermal parameters, constructing a dynamic mathematical model for describing the change in the liquid level of the molten glass includes: Based on the liquid level height of the molten glass in the kiln and the temperature in the kiln, calculate the melting rate of the glass raw materials. Based on the feeding rate of the feeder, the discharge flow rate of the kiln, and the melting rate of the glass raw materials, calculate the net generation rate of the molten glass in the kiln; the net generation rate of the molten glass in the kiln is equal to the result of adding the difference between the feeding rate of the feeder and the discharge flow rate of the kiln to the melting rate of the glass raw materials. Divide the net generation rate of the molten glass in the kiln by the cross-sectional area of the kiln to obtain the dynamic mathematical model.

3. The method according to claim 2, wherein The dynamic mathematical model for describing the change in the liquid level of the molten glass is expressed as: where h(t) represents the liquid level height of the molten glass in the kiln; u(t) represents the feeding rate of the feeder; q d represents the discharge flow rate of the kiln; r(h(t), T(t)) represents the melting rate of the glass raw materials; T(t) represents the temperature inside the kiln; S represents the cross-sectional area of the kiln.

4. The method according to claim 1, wherein Based on the linear quadratic regulator algorithm, calculating the optimal control law that minimizes the objective function of the dynamic mathematical model includes: Linearize the dynamic mathematical model to obtain a state space model; the objective function of the state space model is a quadratic performance index function. Obtain the state transition matrix and control input matrix that make up the state space model. Obtain the state weight matrix and control input weight matrix that make up the quadratic performance index function. Based on the state transition matrix, the control input matrix, and the state weight matrix, solve the Riccati equation to obtain the solution of the Riccati equation. Based on the solution of the Riccati equation, the control input matrix, and the control input weight matrix, generate the optimal control law.

5. The method according to claim 1, wherein Also including: Set specific constraint conditions according to the actual process requirements and equipment operation limitations of the kiln; the specific constraint conditions include the feeding rate constraint of the feeder, the capacity constraint of the kiln, and the liquid level constraint of the molten glass. Under the specific constraint conditions, based on the linear quadratic regulator algorithm, calculate the optimal control law that minimizes the objective function of the dynamic mathematical model.

6. The method according to claim 1, characterized in that Based on the optimal control law, adjusting the liquid level height of the molten glass in the kiln includes: Based on the optimal control law, generate multiple control instructions in the glass production process; the multiple control instructions in the glass production process include motor speed control instructions, valve opening control instructions, and feeder start-stop frequency control instructions. In response to the motor speed control instruction, adjust the feeding rate of the feeder. In response to the valve opening control instruction, adjust the discharge flow rate of the kiln. Optimize the start-stop time interval of the batcher in response to the start-stop times control instruction of the batcher.

7. The method according to claim 4, wherein It also includes introducing an adaptive adjustment mechanism to suppress external interference of the system, and the processing steps of the adaptive adjustment mechanism include: Real-time monitor the unstable factors affecting the glass production process; the unstable factors include the composition fluctuation of the glass raw materials, the change of the thermal environment of the furnace, and the abnormality of the discharging flow rate of the furnace. Based on the unstable factors, dynamically correct the state transition matrix and the control input matrix that constitute the state space model, and the state weight matrix and the control input weight matrix that constitute the quadratic performance index function.

8. A kiln furnace glass liquid level control device, characterized in that, It includes: A data acquisition module for acquiring the structural parameters and thermal parameters of the furnace; the structural parameters include the cross-sectional area of the furnace. The thermal parameters include the liquid level height of the glass liquid in the furnace, the temperature in the furnace, the feeding rate of the batcher, and the discharging flow rate of the furnace. A model construction module for constructing a dynamic mathematical model for describing the change of the glass liquid level based on the structural parameters and the thermal parameters; the objective function of the dynamic mathematical model is used to measure the deviation between the actual liquid level height and the ideal liquid level height of the glass liquid in the furnace. A model optimization module for calculating the optimal control law that minimizes the objective function of the dynamic mathematical model based on the linear quadratic regulator algorithm. A liquid level control module for adjusting the liquid level height of the glass liquid in the furnace based on the optimal control law.

9. A terminal, characterized in that, It includes: A processor and a memory; The memory is used to store a computer program; The processor is used to execute the computer program stored in the memory, so that the terminal executes the method according to any one of claims 1 to 7.

10. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the program is executed by the processor, it implements the method according to any one of claims 1 to 7.

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